Service manual. Piston detectors

Transcription

1 Piston detectors with adapters, optionally with cable break protection Service manual DE FR Universal Piston Detector /4 L+ L- /4 L+ L- D W OAD Further language versions can be found on the SKF homepage. Weitere Sprachversionen finden Sie auf der SKF-Homepage. D autres versions linguistiques disponibles sur le site SKF. Bipolar Piston Detector (4) 4() L+ L- IMPORTANT NOTE! For use only in combination with SKF lubrication pumps of series KFAS/KFBS/KFGS in the commercial vehicles and farm machinery. FR ES NL IT ZH FI EL YES RU PL

2 EU Declaration of Conformity in accordance with Directive 04/0/EU Annex IV EU Declaration of Conformity The manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Plant, Heinrich-Hertz-Str. -8, DE Walldorf, hereby declares conformity of the electrical device Designation: Piston detector Type: Magnetic sensor M...G Item number: and Year of manufacture: See rating plate with all relevant harmonization legislation of the European Union at the time of placing on the market. Furthermore, the following Directives and (harmonized) standards were applied in the applicable areas: 0/65/EU RoHS II Standard Edition DIN Correction 0 DIN Walldorf, March, 08 Jürgen Kreutzkämper Manager R&D Germany SKF Lubrication Business Unit Stefan Schürmann Manager R&D Hockenheim/Walldorf SKF Lubrication Business Unit - -

3 Masthead Masthead Manufacturer SKF Lubrication Systems Germany GmbH Address of manufacturer plants Headquarters Walldorf Plant Heinrich-Hertz-Str Walldorf Germany Tel: +49 (0) 67-0 Fax: +49 (0) Berlin Plant Motzener Strasse 5/7 77 Berlin Germany Tel. +49 (0) Fax +49 (0) Copyright Copyright SKF All rights reserved. Warranty The instructions do not contain any information on the warranty. This can be found in our General Terms and Conditions. This service manual must be enclosed with the product documentation (e.g., feeder documentation). Disclaimer of liability The manufacturer shall not be held liable for damage resulting from: Improper usage, assembly, operation, configuration, maintenance, repair, or accidents Improper reaction to malfunctions Unauthorized modifications to the product Intentional or gross negligence Use of non-original SKF spare parts The maximum liability for loss or damage resulting from the use of our products is limited to the purchase price. Liability for indirect damage of any kind is excluded. Hockenheim Plant. Industriestraße Hockenheim Germany Tel. +49 (0) Fax +49 (0) Lubrication-germany@skf.com - -

4 Explanation of symbols and signs Table of contents Table of contents General warning Wear personal protective gear (face mask) Wear personal protective gear (gloves) Wear personal protective gear (protective clothing) Pressure injection Hot surfaces Symbol Meaning Chronological instructions Bullet list items Indicates the requirements that must be met for the actions described in the following General notes Warning level Consequence Probability DANGER Death, serious injury Immediate WARNING Serious injury Possible CAUTION Minor injury Possible NOTE Property damage Possible EU Declaration of Conformity Masthead Explanation of symbols and signs 4. Safety instructions 5. Scope of delivery/storage 5. Storage 5. Overview, functional description 6. Progressive feeder overview with universal piston detector or bipolar piston detector Design 7.. Function 7. Application in commercial vehicles or farm machinery in combination with a KFAS/KFBS or KFGS pump 8.4 Information on feeder series VP; VPB; VPK; PSG; PSG; PSG 8 4. Technical data 9 4. General technical data 9 5. Assembly 5. Assembly of the new piston detector 5. Disassembly of the old piston detector 5. Conducting initial functional test 6. Malfunctions, causes, and remedies 4 7. Spare parts 5-4 -

5 st Safety instructions /. Delivery and storage. Safety instructions To convert the piston detector, consult the documentation for the feeder (lifecycle manual, assembly instructions) in which the old piston detector is used. The safety instructions in that documentation must be observed in full. Further: The operator must ensure that these conversion instructions and the corresponding feeder documentation have been read by the person who converts the piston detector or supervises or instructs said person. Before removing the defective piston detector, depressurize the affected feeder. The operator must also ensure that the staff fully understands the content of the instructions. Putting the products into operation or operating them without having read the instructions is prohibited.. Scope of delivery/storage The conversion kit for the piston detectors includes a feeder-specific adapter. The piston detectors may be used only with this adapter. A stopper and a cable adapter are also enclosed for the feeder version. The scope of delivery also includes these conversion instructions.. Storage Storage conditions- See feeder documentation and: Store in the original product packaging. Store protected from nearby sources of heat or cold. The permissible storage temperature range corresponds to the operating temperature range (see Technical data )

6 . Overview, functional description. Overview, functional description. Progressive feeder overview with universal piston detector or bipolar piston detector VPBM VPK VP SSV Mounting dimensions, universal and bipolar piston detectors, Fig. 5,6 (5,) PSG PSG PSG SSVD SW SW ,5 (5,5) 5,5 (5,5) SW SW ,8 (5,5) 5,8 (5,5) SW SW (9,5) 54, (54) 54, (54) SW SW (...) = mounting dimension of previous piston detector - 6 -

7 . Overview, functional description. Design.. Function The universal piston detector and the bipolar piston detector are position sensors that, together with the respective pressure-resistant adapter, are screwed into the feeder. Through the closed adapter, the sensors detect the feeder piston without coming into direct contact with it. Hydraulic pressure spikes therefore do not act directly on the front sensor surface the piston detectors. There are different adapters depending on the feeder series. These differ in terms of thread size and clearance. They are specifically tailored to the respective feeder type and piston type. The piston detectors automatically detect the clearance between the feeder piston and the piston sensor following several feeder strokes and adjust themselves automatically. ment, -wire design or -wire design (with cable break protection). The universal piston detector is not suitable for usage in vehicles with KFGS or KFGL lubrication pump due to an undefined pin assignment. The bipolar piston detector is to be used in this case. The bipolar piston detector is available only in a -wire design. The signal voltage can be applied to either pin or pin 4. When the piston detector is actuated (piston stroke), a yellow LED lights up and indicates correct functioning of the piston detector. If a piston detector with adapter is already installed, the piston detector can be replaced subsequently during operation. The adapter must not be removed while removing the existing piston detector! Problems cannot occur in the stopper pressure range of the sensor surface/feeder. The piston detectors are available with a corresponding adapter and cable harness (cable harness only on feeder series SSV/ SSV D) as a replacement for all previous detectors of feeder series PSG, PSG, PSG, VP, VPK, VPB, SSV, and SSV D. The universal piston detector automatically detects the customer s plug/cable assign

8 X BN F 5 KFGS DK BU PK SL,4 W YE PS BK BN Brown 5 Red/Black DK Blue 4 SL Pink 5 ZDS(+) Yellow 6 ZDS Black 7 SL Purple/Green Heinrich-Hertz-Str. -8 DE Walldorf Tel.: +49 (0) 67-0 Fax: +49 (0) Lubrication-germany@skf.com + SL,4 W max KFAS KFBS KFGS (4) 4 () Bipolar piston detector PN: /4 Universal piston detector PN: Pump cable harness, pin 5 (+), wire color yellow =>> =>>piston detector cable harness, pin, wire color Pump cable harness, pin 6, wire color black =>> brown =>> piston detector cable harness, pin 4, wire color black or: L+ L- L+ L- (+) BN Brown WH White BL Blue 4 BK Black. Overview, functional description. Application in commercial vehicles or farm machinery in combination with a KFAS/KFBS or KFGL pump Bipolar piston detector is a replacement for the following piston detectors. Bipolar piston detector Replaces previous piston detectors lights up (actuation of the piston detector), the connection was established correctly. If this is not the case, switch the pin assignment in pin 4 (+) and pin (-) in the power lead..4 Information on feeder series VP; VPB; VPK; PSG; PSG; PSG If the piston detector is mounted (in contrast with its previous mounting position) on the opposite side of the feeder, the feeder piston must also be rotated. See the respective feeder documentation for a description of conversion. If a universal piston detector has been ordered accidentally instead of a bipolar piston detector, inspect it for correct connection before installing it in the feeder. This is done by connecting the electrical plug connection (plug Mx). Then switch on the KFG pump and hold a metallic object in front of the face of the piston detector. If the yellow LED A detailed terminal diagram for connecting the bipolar piston detector to a KFAS, KFBS or KFGS pump is available at the links on page in the respective national languages (attachment to the PDF).!6 7!8 7!GS v+: &%;+ ;u#$ &% 't %() RD-BK o o s So Fu s o s oo VT-GN T=>?@BCl E@CG>C? mh > IJIK=??H B@KH >@BG L@KM N@IKH BE=K=OKH > mh >N P?N I H m I= >@= I QRTUVQRXUVQ RGUL@KM OH BK >Hl PB@K YZ[\] 6 5 C So Fu s o s oo 4 cut!"u#$%& 't %() y*t+,*-+ $,') y-,#. Walldorf Plant 9/0 0/ / C a e C a e < - 8 -

9 4. Technical data 4. Technical data 4. General technical data General data Designation Dimension drawing Field of application Lubricant feeders Ambient temperature [ C] Principle of operation Piston detector/position sensor Material Housing: Stainless steel; plug: PEI Mounting type Mountable flush in associated adapter Tightening torque [Nm] 7 ±0.5 Mx 5 8 8,7 5 M0x0,8 4 Circuit state display LED Yellow/lights up on damping Electrical connection Mx plug-in connection, gold-plated contact LED SW0 8,5 Sensing range Sensing distance [mm].6 condition on delivery Effective sensing distance (Sr) [mm].6 ±0% Sensing distance after x mm strokes [mm]. ±0%, tracked Hysteresis [% of Sr] 0 / 5, tracked Universal piston detector Connector pin assignment without cable break protection -wire DC PNP/NPN Accuracy/deviations Switching point [% of Sr] ±0% Reproducibility [% of Sr] ±0% 4 L+ Permiss. operating pressure with associated adapter [bar] Identical to permiss. operating pressure of the feeder in which the sensor with adapter is installed (see feeder documentation) /4 L

10 4. Technical data Electrical data Universal Piston Detector Bipolar Piston Detector Universal piston detector Design -wire DC PNP -wire DC PNP/NPN -wire DC PNP/NPN Operating voltage [V] 0-6 DC, supply class per culus Power consumption [ma] < 5 Safety class Polarity reversal protection Yes Reverse polarity Output function III NO-contact Voltage drop [V] Minimum load current [ma] 5 Residual current [ma] < 0.8 Current-carrying capacity [ma] 00 Short-circuit-proof Overload-proof Switching frequency [Hz] 0, with damping surface Ø 4mm to 7 Hz Yes Yes Connector pin assignment with cable break protection -wire DC PNP 4 /4 Bipolar piston detector L+ L- Protection class [IP] IP65 / IP68 / IP69K; with cable box screwed on properly 4 (4) L+ 4() L

11 5. Assembly 5. Assembly Assembly drawing, Fig. 5. Disassembly of the old piston detector (VPB/VPK/PSG/VP/PSG/PSG/SSV/SSVD) 5. Assembly of the new piston detector (VPB/VPK/PSG/VP/PSG/PSG) 5. Assembly of the new piston detector (SSV/SSVD) VPB VPK PSG VP PSG PSG SSV D SSV SSVD

12 5. Assembly 5. Disassembly of the old piston detector see Figures and CAUTION Pressure hazard Before beginning conversion work, depressurize the system in which the feeder with the piston detector to be replaced is installed and depressurize the feeder itself. Depressurize the lubrication system and feeder If possible, place a drip pan for the discharging lubricant below the corresponding feeder. Disconnect the electrical connection cable () from the old/defective piston detector. Loosen and unscrew the defective piston detector () from the feeder (4). Only on feeder versions with sealing ring: Remove old sealing ring (5) from the feeder (4) (VP; VPB; VPK; PSG; PSG; SSV D) 5. Assembly of the new piston detector see Figures and Grease the new sealing ring (6) and place it on the new adapter (7). Apply the adapter (7) to the feeder (4) and tighten with the following torque: Adapter torques VP / PSG WAF 7 = 0 + Nm VPK / PSG WAF = 5 + Nm PSG WAF 4 = 70 ±4 Nm SSV / SSVD WAF 4 = 5 + Nm VPB WAF = 5 + Nm Apply new piston detector (8) to the adapter (7) and tighten gently. Place individual parts of the new piston detector replacement kit () on a clean storage surface. - -

13 5. Assembly 5. Conducting initial functional test Avoid uncontrolled tightening of the piston detector, as this could cause damage. Maintain tightening torque of Nm. Attach the adapter cable (9) in a stressfree position. Clean the work area/feeder of lubricant contamination. See Figure The piston detectors automatically detect the clearance between the feeder piston and the piston detector following several feeder strokes and adjust themselves automatically. 5 Tighten the piston detector (8) with a torque of Nm. Connect electrical connection cable (provided by customer) () to the piston detector (8). In case of different cable connection: Remove old connection cable (). Remove the drip pan. The yellow LED on the piston detector lights up to indicate an active feeder stroke. On the subsequent feeder strokes, the signal from the piston detector must be received by the customer s monitoring equipment. Automatic adjustment is performed after power is recovered, e.g., after switching the lubrication system off and then on, and a functional test is no longer required. In place of the previous connection cable, connect the supplied adapter cable (9) to the piston detector (8) and the customerprovided port - -

14 6. Malfunctions, causes, and remedies 6. Malfunctions, causes, and remedies Malfunctions table Malfunction Possible cause Remedy Socket not connected or connected incorrectly Check plug contacts Install socket correctly Signal line is broken Check signal line None Feeder signal Piston detected is not installed correctly Piston detector overtightened Check engagement depth of adapter and piston detector, tighten if necessary Disconnect piston detector, perform functional test, replace piston detector if damaged Wrong adapter used Use only the adapter appropriate for the respective feeder Universal piston detector ordered instead of a bipolar piston detector; only when connecting to KFG pumps in vehicle lubrication applications Swap the pigtails, see Chapter

15 7. Spare parts 7. Spare parts WARNING! Adapter sleeves can be changed only on depressurized feeders! Spare parts list Designation Order number Designation Order number Quantity Universal Piston Detector wire or -wire connection Bipolar piston detector wire connection for vehicle lubrication VP adapter sleeve VP stopper WVN 50-x.5 VPK adapter sleeve VPK stopper WVN 50-0x.5 VPB adapter sleeve VPB stopper WVN50-0x PSG adapter sleeve PSG stopper PSG adapter sleeve PSG stopper WVN 5-x.5 PSG adapter sleeve PSG stopper None SSV / SSVD adapter sleeve SSV / SSVD sealing ring x each 7-5 -

16 Seals Bearings and Bearing Units Lubrication Systems Mechatronics Services July 08 SKF Lubrication Systems Germany GmbH Walldorf Plant Heinrich-Hertz-Str. -8 DE Walldorf Tel: +49 (0) 67-0 Fax: +49 (0) Lubrication-germany@skf.com